Apparatus for dyeing yarn with a controlled sequence of different colours

Abstract

 The apparatus includes a printing machine (2) having a succession of printing stations (13). Yarns to be printed are passed through the printing machine (2) in the form of a ribbon (93) of yarns tied together by soluble cross-fibers. Each printing station includes a pair of rotatable printing rollers which are arranged to be selectively closed together into contact with the yarn ribbon (93), or spaced apart away from the yarn ribbon, by a control device in response to programmed control signals. The printed yarn ribbon (95) is passed through an oven (96) to fix the colours thereon, and the yarn ribbon (98) is then separated into individual yarns. The programmed control signals are generated such that the sequence of colours on the yarn results in a predetermined multi-coloured design when the yarn is used in the production of a textile fabric, for example in an embroidery machine.

Description

[0001] This invention relates to the production of coloured yarns for use on looms and/or knitting or embroidery machines, and is particularly directed to apparatus for dying yarn with a controlled sequence of different colours for the production of textile fabrics with predetermined multi-coloured designs.

[0002] In U.S. patents Nos. 3,788,246 and 3,863,310 there are disclosed apparatus and process for producing multi-coloured yarns for use in Schiffli-type embroidery machines consisting of first producing a punched tape programmed according to colour variations of a pattern to be embroidered on fabric material. The tape is cut simultaneously with a standard tape of the Jacquard type used on these machines. After the colour tape is produced, it is used to control s multi-colour dye system where a continuously moving yarn has the different coloured dyes applied thereto in accordance with the colour tape which controls the application of the dye selectively. After the yarn is completely and selectively dyed, it is inserted back onto the machine in proper sequence and synchronized with the original standard tape so that the needle stitching produces a multi-coloured embroidery according to the original design.

[0003] In the apparatus disclosed in the said U.S. patents the dyes are applied to the yarn by spray nozzles having valves controlled by the colour tape. On the yarns dyed in this manner the definition of the various colours is obviously limited, it is not possible to obtain sharply defined changes from one colour to another at precisely predetermined locations.

[0004] The invention therefore sets out to avoid this drawback and to provide improved yarn dying apparatus permitting to produce dyed yarn in which the various colours in the controlled sequence are clearly and sharply defined with respect to one another at precisely predetermined locations.

[0005] This is achieved according to the invention by apparatus of the kind referred to above and which is characterized by a printing machine including rotatable printing rollers for applying dyes to a moving yarn assembly, in which printing machine the application of each colour dye is arranged to be switched on and off by a control device in response to programmed control signals, and yarn assembly processing devices for receiving the printed yarn assembly to fix the colours thereon and separate the yarn assembly into individual yarns.

[0006] The apparatus may include a computer-type programmable colour printing machine for printing colours on-one or both sides of the yarn in any desired lengths, and in any desired colour sequence, and in which the program may be changed or modified in any manner before or during the printing process without stopping the apparatus for printing. Such a computer programmable printing machine can be programmed to accommodate any pattern or design to be imposed on any yarn undergoing stitching, weaving or knitting by machine.

[0007] The printing machine may have a plurality of equally spaced apart colour printing stations each indicative of a specific colour for printing yarns and each controllable to print colours along the yarn length at selective station or stations and in selective amounts. The machine may be disposed to accommodate yarns in ribbon form for convenience of multiple strands of conveyance and subsequent separation of yarn strands to form a single spool or bobbin of yarn usable on a stitching, weaving or knitting machine.

[0008] The apparatus may conveniently include storage means for storing data relating to the yarn printing machine comprising number of stitches or stitch count, length of stitches, lengths of individual colors, and sequence of colors all pertaining to a particular design or pattern and usable on paper and magnetic tape for controlling the printing machine.

[0009] Preferred embodiments of the apparatus according to the invention will be described hereinafter with reference to the accompanying drawings wherein:

Fig. 1 shows a simple block diagram of the overall system according to the invention.

Fig. 2 is a simple diagrammatic side view of the printing machine and the drying oven for the printed yarns.

Fig. 3 is a simple diagrammatic side view of the washing and drying vats for treating the yarns after printing.

Fig. 4 is a simple diagrammatic side view of the yarn separation and the placement thereof on spools or reels.

Fig. 5 is a diagrammetic side view of the printing machine with the yarn flowing therethrough.

Fig. 6 is a front view of Fig. 5.

Fig. 7 is a construction plan view of a single color printing station showing the printing rollers in their operable position.

Fig. 8 is a constructional front view of the single color station of Fig. 7.

Fig. 9 is a sectional view on line IX - IX of Fig. 8.

Fig. 10 is a sectional view on line X - X of Fig. 8.

Fig. 11 is a sectional view on line XI - XI of Fig. 8.

Fig. 12 is a view similar to Fig. 11 with the rollers separated.

Fig. 13 shows an exploded view of a printing station in perspective.

Fig. 14 shows an alternative system for supplying dye to the printing rollers.

Fig. 15 shows a simplified diagrammatic view of stitching data gathering for use in a computer.

Fig. 16 shows a simplified schematic diagram for computer operation of the printer machine.

Fig. 17 shows a wiring diagram for the controller responsive to computer instructions for controlling the operation of the printing machine.

Fig. 18 shows a system for feeding the printed yarn to an embroidery machine or loom for the fabrication of the finished pattern.

[0010] The overall yarn printing system according to the invention is composed of a plurality of separate component parts integrated into an operable system although each component can comprise an entity useful unto itself. The system consists of first producing a specific program indicative of a specific design or pattern having specific colour variations, such variations being indicative of numbers of stitches, stitch length, colour lenghts in each stitching and types of colour variations and/or blending to give the specific effects desired. The program as such is then placed into a suitable computer for producing the required impulse variations necessary to activate a controller mechanism. The controller in response to the computer impulses produces the necessary control voltages which in turn controls the operations of the colour printer device.

[0011] The colour printer device or mechanism is the heart of the overall printing, it is the mechanism that actually prints the various colours in accordance with the desired plan or pattern. The printer comprises a plurality of vertically oriented colour printing stations spaced apart a fixed finite distance, each station consisting of a pair of side-by-side abutting rollers disposed to rotate inwardly and opposite to each other, each station having a source of colour dye in which one or both rollers may be in contact with for printing. The rollers are constantly driven from a fixed motor-drive source and made to abut and separate under the influence of pressurized air which is in turn under the control of the control voltages emanating from the controller. The printer effects the colour printed, the length of the colour printed and the colour sequence printed all under precise controls.

[0012] The colour stations as disposed are unique in that the displacement between them is a constant and fixed, and are relevant to the positioning of colour as the yarn moves along from station to station. Since the colours from station to station are different, and the printing for a given design may vary over any given design length, the ability to permit printing over a given length during one time period may be different from printing over another time period. However, since the distances between stations are fixed, they must be considered indiginous to the system for the purpose of identifying a particular program. Assume that the colour stations are numbered 1 through 6 from top to bottom and the yarn assembly or ribbon is traveling from top to bottom, then colours printed in numerical sequence will require a timing lag; colours printed in reverse numerical order will require a timing lead.

[0013] For example: If colour No. 1 is printing and the next colour is No. 2, it will be necessary to stop No. 1 and wait until the yarn ribbon travels a distance A (distance between stations) before No. 2 is actuated. If the next colour is No. 3 instead of No. 2, then the wait would be 2xA. Conversly if No. 5 colour is followed by No. 2, then No. 2 will start printing 3xA distance before No. 5 stops. This _'lead and lag timing will be controlled through a program for the computer or from stored data banks to be used with the computer. This idea and others will be better understood from a description of the drawings herein, keeping in mind like parts will have the same reference numbers throughout the respective drawings.

[0014] After the printing process has taken place, the yarn ribbon is fed through an oven where the colour dye, causing the printing, is dried and fixed or developed. The ribbon is then wound on a reel which is rotated by a torque motor. Actuation of the colour stations is as follows:

(1) The rollers are caused to rotate by magnetic clutches.

(2) After a time delay which allows the rollers to pick up dye from a dye source, the rollers are pressed against the yarn ribbon by an air cylinder.

(3) When the printing operation is complete, the rollers open up by action of the air cylinder, and stop turning. Two sets of feed rollers are operated in the same manner. Instead of colour boxes or receptacles, the source of dye may be in the form of a container, placed above the roller, and dye emitted therefrom under the control of air pressure. Further means in proximity to the roller may control the thickness of the film along the roller surface, therefore controlling the film thickness of dye along the yarns.

[0015] After the ribbon is printed and dyed, it is moved to the rinse cycle where it is washed and reeled as individual yarns. The wash cycle consists of three tubs, two cold and one hot. To insure that the yarn stays together until it exits, in the drying oven there is a continuous net-tape (transport tape) which passes through the tubs through the ovens, under the oven and tubs, to return to the start. The dyed ribbon will be clipped to this transport tape at the start of the rinse cycle and will be taken from the tape as it exits the oven. It will be individual yarns at this point and then fed by hand to the yarn reeler.

[0016] In the second tub, the hot tub, the cross fiber in the yarn ribbon will dissolve, and at this point the ribbon will, e.g.,become sixty-four yarns. The transport tape will carry it on through the system until it leaves the transport tape after the oven. The yarns as dyed are suitable for use on stitching, weaving and knitting machines; these yarns are considered the warp yarns as opposed to weft yarns which are singular. However, the weft yarn can be made transverse to the elongated ribbon, so that the length thereof can be considerable compared to the elongated ribbon. Here the warp (elongated) yarns are made soluble, so that the tran sverse weft yarns produced will be very long to provide the desired length of yarn for weaving.

[0017] In each of the tubs there is a unique spiral wheel which is disposed to expose as much material as possible in a given amount of time. The rinse cycle is independent of the print cycle, but they are arranged so as to use the same drying oven, hence only one oven is necessary. The spools of the two cycles need not be the same. The yarn reeler will be driven by a torque motor. The transport tape in thennse cycle will be driven by the two rollers at the bottom of the oven and the roller as shown in the drawings.

[0018] Now describing the invention in more detail relative to the drawings there is shown in Fig. 1 an overall system block diagram which includes a computer and control unit 1 connected to a printer and colour set 2 which in turn connects to a wash and dry mechanism 3 and finally terminates in a yarn reeler 4 for the yarn to be used in a stitching machine 5.

[0019] Figs. 2 and 5 - 13, show the actual colour printer mechanism and the structured apparatus for actually colour printing or dying the yarns under strict control conditions under a specified program stored in the computer. The computer, the programming thereof, and the controls for actuating the printer mechanism in response to the program will be described later after the mechanics of the actual colour printer is described.

[0020] The printer 2 comprises a structural frame 10 having a pair of spaced apart upright beams 11, 12 (Figs. 5, 6) supporting between them a series of colour stations 13, each station being composed of a colour dye source and apparatus for dye printing yarns. The yarns are printed in a specific colour sequence in accordance with a program generated for a particular pattern or design configuration.

[0021] The colour station 13 comprises a pair of abutting oppositely rotatable rollers 15, 16 (Fig. 7) each supported by shafts 17, 18 each of which is journaled in and supported by support brackets 19, 20 which are in turn carried by a support plate 21 bridged across and supported by upright beams 11 and 12.

[0022] The support shafts 17, 18 have connected thereto at one of their extremities a pair of driven spur gears 22, 23 driven by driver gears 24, 25 each of which is connected to shafts 26, 27, said shafts being journaled in and supported by the brackets 19 and 20.

[0023] I Driver gear 25 is driven selectively by a master driver gear 28, the master gear being connected to shaft 29, the said shaft being journaled in and supported by bracket 20 and a bracket 30 which is tied to upright beam 12.

[0024] The shaft 29 further carries a clutch mechanism 31 and a helical type gear 32, the said helical gear 32 being driven by a worm gear 33 which is connected to and forms a part of an elongated rotatable shaft member 34, the said shaft member 34 parallels the upright beam 12 and terminates in and is driven by an electric motor 35.

[0025] The clutch mechanism 31, interposed between the helical gear 32 and master driver gear 28, is for the purpose of disengaging the said helical and master gear to stop the rotation of the rollers 15, 16 under circumstances where manual or selective operation of each of the colour stations 13 is desired.

[0026] In proximity to and below each of the respective rollers 15, 16 lies a receptacle or colour box 60, 61 each carried by a support plate 21, the said colour boxes being receptacles for colour dye sources. Although the colour dye source is shown in the form of colour boxes or receptacles, other colour dye sources and the feeding thereof to the rollers are available and will be further described herein at a later time. The rollers are each in their respective movements and rotation disposed to engage and carry dye from the dye sources, in this case the colour boxes, and transmit same to the particular yarns to be printed or dyed in accordance with the particular sequence and length as dictated by the original program design.

[0027] The printing rollers 15, 16 each have respectively connected to their outer extremities along their supporting shafts, 17, 18, a linkage system 40, 41 for the purpose of causing the rollers 15, 16 to engage and dis-engage each other depending upon when printing colour dye is or is not to take place. The linkage system is comprised of elongated links 42, 43 the ends 44, 45 of which are connected to the shafts 17, 18, respectively. Comparable links are also connected at their extremities to the other extremes of shafts 17, 18.

[0028] The links 42, 43 each have their other extremities pivotally bolted to a connector 46, the connector in turn being attached to a shaft-like plunger 47 which is in turn tied into and driven by a pressure actuated dual movement or reciprocal action fluid ram 48. The same ram-linkage mechanism resides on the other sides of the respective rollers to cause the movement thereof to be hereinafter described. The fluid ram 48 has an air-pressure source not shown, pressure air entering the ram to cause the activation thereof selectively.

[0029] The shafts 17 and-26, and 18 and 27 are each interconnected at the roller extremities and linked by pivotal suspension link supports 50, 51 and 52 and 53, respectively, the support links carrying the rollers in a suspended manner so that the said rollers abut and contact each other along their outer periphery along a line-contact. The suspended rollers have a slight angular freedom of movement, allowed by the pivotal suspension supporting links, but also because of the slightly elongated slots 55, 56, in the brackets 19, 20, in which the shafts 17, 18 are journaled or supported.

[0030] The abutting rollers 15, 16 are in normal contact by reason of their suspension and gravitational effect, causing the rollers to normally swing together on their support suspension links 50, 51 and 52, 53. To spread the rollers apart so that there is no pressure contact between them, the ram-linkage systems 40, 41 are so designed as to cause the rollers to spread apart under the influence of compressed air selectively applied in a manner to maintain the spread over a time span in accordance with the program selected. Colour printing is accomplished while the rollers are in contact, and printing ceases when the rollers are spread apart, although the yarn undergoing printing is continuously moving through the colour stations and the machine itself.

[0031] The ram-linkage mechanism 41 functions in the following manner, the reciprocal fluid ram 48, in which air can cause the ram to function in a dual fashion, causes the plunger mechanism 47 to move up or down depending on the valve-cock withing the ram which deflects the air for either up or down movement. As shown in the respective figures, especially Fig. 13, when the plunger 47 is driven upward, the elongated links 42, 43 are caused to be deflected outward so that the shafts 18, 19 are correspondingly deflected or urged outward, and the rollers 15, 16 carried thereby spread apart. This spread apart, no contact of the rollers, remains in this state so long as the air continues to flow through the ram, and the valve cock maintains its position. The valve cock is in turn controlled by a special control system to be described later. Reversal of the air-flow causes the plunger to move downward and the rollers are once again in pressure contact with each other.

[0032] During the process of causing the spread-apart movement of the rollers, the gearing arrangement controlling the movement of the rollers remains intact, all gears continuing to mesh according to their intended functions. The spur gears 22, 23 are spread apart, but they remain in contact with driver gears 24, 25 and master drive gear 28 also remains in contact with gear 25. All gears continue to function as intended during the spreading action of the rollers, thus continuing the rotation of the respective rollers.

[0033] Each of the respective rollers 15, 16 have in proximity thereto colour receptacles or boxes 60, 61 respectively for storing or containing colour dye 62, 63 which dye adheres to and forms a thin film of colour dye on the roller surface as the roller dips into the receptacles selectively. Excess dye or film thickness or the removal thereof is accomplished by the use of blade-like members 64, 65 each hingedly attached to a side of the receptacles by biased hinges 66, 67.

[0034] Another colour or dye source configuration is shown in Fig. 14 which provides an injection type dye source also located in proximity to the rollers, and although a dual system is possible and may be preferred in certain arrangements herein, for the-purpose of describing this embodiment only a single injection source will-be shown and described as per Fig. 14. The injection dye source comprises a transparent container 70 made of plastics, glass or some other material capped by cover 71 having an input 72 connected to an air-supply 73 under pressure, the air--pressure being controlled by a pre-arranged and/or programmed control. The colour dye 74 within the container 70 is forced through a funnel-like chamber 75 causing the dye to undergo a restrictive movement through conduit 76, the conduit thereafter terminating into an elongated valve-like mechanism 77 which is designed to permit a film flow of colour dye onto the roller of varying thicknesses by the exercise and control of the gap 78 through which the dye must flow. The gap 78 is controlled by a pivotally operated lever 79 having an elongated arm 80 connected thereto which controls the gap size through which the dye must flow.

[0035] Beneath the rollers and in proximity thereto lies a receptacle box 81, sitting on support plate 21 of the colour station 13, the said receptacle being available for collecting excess dye and scraping from the roller after a dying operation. After each dying operation it is necessary and advisable to remove the residue dye before applying a new and/or different dye. This is simply done by the use of a doctor blade 82 hingedly connected to the receptacle. The residue dye may be conveniently removed by other means such as the use of a vacuum source to remove the dye.

[0036] The colour dye source container 70 is so disposed as to be conveniently removed from the holding chamber 75, and a new container placed therein and the cap 71 placed thereon. Hence, convenient colour dye source is available in a very short period of time.

[0037] It is possible to have other methods for printing dye on the yarns, whether the dye is liquid or dried such as in the types used in "Xerox" machines. These dye types may be those available as charged particles, or thermal methods can also be used to colour print the yarns.

[0038] The colour stations 13 as above described do not include stations 90, 91 (Figs. 2, 5) which stations in effect are identical to the colour station 13, but there appears at the stations 90, 91 no source of colour dye. These stations and the rollers appertaining thereto are for the purpose of starting the yarn flow through the printer since these particular rollers arein constant operation once the machine starts, whereas the colour stations are not, but only become operative or functional when a particular colour or dye is to be printed upon the yarn as it passes through the rollers.

[0039] As shown in Figure 2, the yarn assembly 93 enters the printer 2 from a reel 94 upon which the multiple yarns are stored in the form of a ribbon arrangement, and the printed yarns 95 exit from the printer to pass into and through an oven 96. The yarns pass into a helical type wheel 97 specially arranged to accommodate longer lengths of yarns for a fixed oven area, the yarns undergoing a heating process which fixes the colour dye thereon. The fixed exiting yarns 98 are than stored on a yarn storage reel 99, the reel being rotated by a motor and pully arrangement 100 for reeling in and storing the exiting fixed coloured yarns 98.

[0040] Figs. 3 and 4 show the process for preparing and separating the yarns for either storage or for use whatever the case may be. The fixed printed yarn 98 from reel 99 is passed through a series of washing vats or tubs 101, 102, 103 for purposes of separating the individual coloured yarns from their ribbon form so that the individual yarns may be properly and suitably reeled onto separate reels. It may be mentioned here that a plurality of strands of yarns are placed side-by-side to form a ribbon, the strands held together by soluble cross-fibers. The cross-fibers are actually weaved into the yarn strands to form a ribbon--like material composed of multiple yarn strands. Printing in this fashion permits a large number of strands to be printed at one time. It may also be convenient at this time to have the aid of a net-type transport tape to carry the ribbon-like yarns during the wahing and drying process to assure that the individual yarn strands do not separate before it is time to do so. Hence the transport tape will follow the same path that the ribbon takes.

[0041] In Fig. 3 the tape is passed through the first washing tub 101 containing cold water to remove any excess dye material. The tape is then passed on through the second wash tub 102 which contains warm or hot water to cause the cross-fibers in the ribbon to dissolve so that the yarns are individually contained, and finally the ribbon passes through the final wash tub 103 containing cold water which removes the residue of the soluble cross-fibers. In each of the tubs, the ribbon passes over and is transported by a unique type helical wheel 104 which is able to transport and carry agceat length of ribbon during the washing and drying process. Finally the ribbon 105 containing the individual yarn strands exiting from the washing tubs passes through a final drying process within an oven 106; this oven may also be the same oven 96 previously mentioned with respect to Fig. 2, or can be a separate one. The yarn strands in ribbon 105 are then conveniently separated by separator means 107, 108 (Fig. 4) so that the individual strands are reeled in by separate reels 109 and stored thereon.

[0042] To colour print the yarns, the colour printing machine must be commanded in a fashion to print the yarns according to a pre-arranged design, and to accomplish this design, a special program must be prepared to function within a specialized computer which in turn will operate special control devices which manipulate the printing machine to create the desired colour effect on the yarns.

[0043] The program for printing the yarns is comprised of four parts namely (1) data gathering, (2) data refinement, (3) colour printer operation and (4) yarn flow control. The program and design data are stored in the memory of a computer device manufactured by the "Gould Corporation" and called the "Modicon 584 Programmed Controller". Fig. 16 shows, for illustration purposes only, a block diagram showing the memory of the computer divided into four sections "A", "B", "C", and "D". Although the entire program is considered as one written program, it can be operated in four parts. The basic program and data at any stage may be recorded on magnetic tape.

[0044] Referring to Fig. 16, section "A" of the computer memory, the said memory receives raw data from three input sources 110, 111 and 112. Input 110 represents stitch count as initiated by a needle switch which initially comes from a needle bar 114 of a design punch machine shown and illustrated in Fig. 15. The colour selection,input 111, is determined by pushing one of seven pushbuttons from a panel 115 operated by the design punch machine operator, again as shown in Fig. 15.

[0045] Before proceeding further with the data applied to the memory bank of the "Modicon Computer 584", as illustrated in Fig. 16, the raw data information is generated by the system as shown in Fig. 15. In particular Fig. 15 shows a fabric piece 116 having a particular pattern or design 117 made up of different coloured yarns. By suitable pantograph means the design pattern is traced out by a needle bar 114 on a stitch-by-stitch basis. Each time a stitch is made, the needle switch 113 shown in Fig. 16 is closed so that a pulse-like signal is fed into the memory bank "A". The number of stitches for a particular yarn length is determined by the arrangement shown in Fig. 15. The needle bar 114 has attached thereto a yarn 120 wrapped around a felt roller 121 carrying at one extremity thereof a gear wheel 122 in mesh with another gear wheel 123 at a 5 to 1 reduction. The gear wheel 123 is connected to a perforated disc wheel 124 by a shaft 125, the perforations126 being peripherally spaced a distance representative of a particular yarn length in millimeters, preferably, but not necessarily, 0.25 mm. Each indexing of the wheel 124 by one perforation permits an interruption of a light beam from a source 127 directed to a photo-cell 128, supplying a signal to input 112 in Fig. 16.

[0046] Thus what has been acquired from the foregoing are five sets of data stored in the memory bank of the "Modicon 584" programmed controller. All data are stored as numbers in registers of the 584 controller, namely (1) number of stitches, (2) length of each stitch, (3) colour sequence as dictated by the particular design or pattern, (4) colour length, i.e. length of yarn for each colour as it appears in the pattern, and (5) total yarn length corrected for colour box position in the colour printing machine. Section "A" of the 584 memory has all this data stored therein and the data can be used immediately, or recorded on magnetic tape for future use.

[0047] The total yarn length for each colour change represents a set of data or cumulative yarn lengths at the point of each colour change. These lengths have been corrected for colour stations in the printing machine, thus resulting in a table of numbers which are not in numerical order. The operating program for the printer will use these lengths to index the start of the next colour, therefore they must be arranged in numerical order. This is arranged in Section "B" of the 584 computer shown in Fig. 16. A sort program is included in the total program to rearrange the cumulative lengths in numerical order. The same sort program will rearrange the colour sequence to agree with the rearranged cumulative lengths. This is accomplished automatically by the 584 computer after the sort start switch 130 is activated. A reset switch 131 is provided after the sort is complete so that the program can sort a second set of data. Also by altering the sort program a second design can be made from the original raw data. After the raw data has been sorted it is stored in the memory of the 584 computer, and is ready to be used to operate the colour printing machine.

[0048] Three sets of data are used in the program to operate the colour printer machine, (1) rearranged cumulative lengths, (2) rearranged colour sequence, and (3) colour lengths, and these are forwarded to Section "C" of the 584 computer as shown in Fig. 16. The program also provides manual switches 150, 151 and 152 for start, pause and reset. When the start switch 150 is activated, the 584 computer will start the feed rollers in stations 90, 91 of the colour printer 2 shown-in Fig. 5, and at the same time it will take the first number from the length table in the computer memory shown in Fig.-16. It will then time out until the elapsed time in 0.01 seconds equals the above first number. It will then take the second length number'and at the same time select the first colour from the memory bank. This will actuate the colour rollers in the selected one of stations 13 shown in Fig. 5 which will operate to print the desired length of colour which was stored in the raw data memory.

[0049] The program will then time out to the second length number and then select the third length number and the second colour. This process will continue until all length numbers and colour sequence numbers have been used. The program process will stop and sound an alarm. Due to the design of the colour printing machine 2, when the colour stations 13 are spaced 10.5 inches (267 mm) apart, it is possible when printing short lengths of colour for two stations to be printing simultaneously, or waiting for a lower level station to print whenit is next in sequence. This feature is provided for in the program.

[0050] If it is necessary to interrupt the operation, the pause switch 151 is turned on. To continue operation, the pause switch is turned off. To repeat the sequence, the start switch 150 is turned off, the reset switch 152 is turned on and then off. After this the start switch 150 is again turned on.

[0051] The speed of the colour printer is designed so that one unit of yarn length flows through the machine each 0.01 seconds. The Modicon 584 computer communicates to the colour printer through a relay box 160 with eight conductors 161 passing from the relay box to the colour printer 162 as shown in Fig. 16, each of the separate conductors 161 representing a separate control for each of the colour stations 13, and a common ground. The computer through computer contacts Cl, C2, C3 and etc. operates suitable relays in relay box 160 which is shown schematically by Fig. 17 to be further described. The controls from the relay box 160 actuate the selected magnetic clutches 31 indicated in Fig. 7, and air valves 40, 41. The colour printer operate program ("C") is part of the overall program stored in the memory of the 584 computer.

[0052] Referring now again to Fig. 16, the yarn flow program Section"D" of the 584 computer receives its input from Section "A" where raw data has been stored. This part of the program, yarn flow program, is independent of the printer control program, but is part of the overall program. This part of the program uses the number of stitches and stitch length data in the raw data part Section "A" as above stated. The program is commenced by turning the start switch 170 connected to Section "D". The purpose of the yarn flow program is to control the flow of the printed yarn into the embroidery machine. It does this by controlling the rotation of the felt roller 171 of the embroidery machine through a stepping motor 172 as shown in Fig. 18. The printed yarn when used by the loom or embroidery machine, whatever, the stich- ing process must be synchronized with the computer memory program which controlled the printing process.

[0053] Again referring to Fig. 16, Section "D", the yarn flow program, after the start switch 170 is turned on a micro switch attached to the needle bar, not shown, of the embroidery machine will select the first stitch from the 584 memory. The program will then index the stepping motor 172 of Fig. 18, the number of units of yarn length specified by the first stitch length. In the second stroke of the needle bar, the micro switch will select the second stitch length and the operation will repeat until all stitches have been used from the computer memory. The computer communicates with the stepping motor through a stepping motor control 173. The stepping motor indexes one step each time the relay computer contact 174 closes. After all the stitches have been withdrawn from the memory, Section "D", the process can be stopped by turning the start switch 170 off, or can be repeated by turning the reset switch 175 on and then off.

[0054] The control relay box 160 shown in Fig. 16 is in part schematically illustrated by Fig. 17 and is shown how it receives commands from the computer so as to control the printer movements and the magnetic clutch arrangements associated therewith. In the diagram of Fig. 17, the circuits are repeated for each section so that it would suffice to explain one. Each of the control sections is tied into and identifiable with each of the colour stations 13 of Fig. 2, but also the stations 90 and 91 having to do with moving the yarn at a uniform speed and the control thereof. Assume computer relay 02 closes and through an auto-manual switch 180 it will pick up relay 181. Contact 182 of relay 181 will close the D. C. circuit 183 of magnetic clutch 2MC (clutch mechanism 31 in Fig. 7) which starts the printing rollers turning. A second contact 184 of relay 181 energizes a coil 185 which times out for 2.6 seconds, after which time a control coil 186 for the down side of fluid ram 48 is activated through a normally open contact 187. This closes the rollers 15, 16 together to start printing. A third normally open contact 2b of relay 181 will pick up relay 191 of the first section, which then simultaneously operates the first station 90 of printer 2 as shown in Fig. 2, when any of the printers 13 of said figure are operating. When the computer contact C2 of section 2 in Fig. 17 opens, relay-181 drops out and this in turn drops out timing relay coil 185 which opens the printing rollers of the second station 13 by activating a control coil 192 for the up-side of ram 48 through a normally closed contact 193 of timing relay coil 185. When relay 181 drops out this also stops the magnetic clutch 2MC. Normally open contacts of 2b, 3b, 4b, 5b, 6b, and 7b shown in section 1 of Fig. 17, are parallel so as to activate the circuits of the first station 90 of Fig. 2 when any of the colour printing stations 13 are operative.

[0055] Switch 180 in Section 2 of Fig. 17 to manual operation will permit bypass of the computer contact C2 and the operation as above defined will be duplicated.

Claims

1. Apparatus for dying yarn with a controlled sequence of different colours for the production of textile fabrics with predetermine multi-coloured designs, characterized by a printing machine (2) including rotatable printing rollers (15, 16) for applying dyes to a moving yarn assembly (93), in which printing machine (2) the application of each colour dye is arranged to be switched on and off by a control device (160) in response to programmed control signals, and yarn assembly processing devices (3, 4) for receiving the printed yarn assembly (95) to fix the colours thereon and separate the yarn assembly (95) into individual yarns.

2. Apparatus according to claim 1, further characterized by computer means (Fig.16) for receiving signals-indicative of said sequence of colours and processing these signals taking into account the distances between the dye applying locations (13) in the direction of movement for producing control signals for the control device (160).

3. Apparatus according to claim 2, further characterized by data gathering means (Fig. 15) for scanning a sample (117) of the design to be produced in said textile fabric and generating said signals indicative of the colour sequence.

4. Apparatus according to claim 3, characterized in that said data gathering means (Fig. 15) includes stitching means (114) for tracing out said sample (117) to produce a finite number of signals indicative of said stitches encompassing the whole of said design and comparative signals indicative of the length of said stitches, the said signals being transmitted and stored in the computer means (Fig. 16) for subsequent retrieval and control of the printing machine (2).

5. Apparatus according to claim 4, characterized in that said data gathering means (Fig. 15) further includes colour selection means (115) for producing signals indicative of colour and lengths of the sample (117)during the needle stitch tracing out process, the said signals being transmitted to and stored in the computer means (Fig. 16) to be used in conjunction with the said stitch numbers and stitch length for control of the printing machine (2).

6. Apparatus according to claim 5, characterized in that said computer means (Fig. 16) includes computer register means (A) for receiving the said signals indicative of colour sequence in the form of stitch numbers, stitch lengths, colour selection, and length of colour selection for each stitch length, the said signals being stored in said register means (A) for processing to produce said control signals.

7. Apparatus according to claim 6, characterized in that said computer means (Fig. 16) includes registers (B) for processing raw data into refined data and the combined data producing the control signals.

8. Apparatus according to claim 7, characterized in that said control device (160) includes circuit means for receiving the control signals and producing control voltages indicative of the program data for selective operation of the printing machine (2) for colour printing of the yarn assembly (93) according to the scanned design (117).

9. Apparatus according to claim 8, characterized in that said printing machine (2) includes a plurality of colour printing stations (13) each disposed to receive said control voltages and each having colour dye printing rollers (15, 16) for colour printing the yarn assembly (93) in response to said control voltages as the yarn assembly moves from station to station.

10. Apparatus according to claim 7 for printing an assembly of yarns held together by soluble cross-fibers, characterized in that the printing machine (2) comprises a plurality of vertically stacked spaced apart colour printing stations (13) each supported by a frame (10) having spaced apart vertical supports (11, 12), the said stations (13) each bridged across and carried by said supports (11, 12), each station (13) comprising a pair of suspendable shaft supported abutting rotatable printing rollers (15, 16) pivotally connected to fixed support shafts (26, 27) by linkage means (50, 51, 52, 53), the said fixed support shafts '(26, 27) each journaled in spaced apart vertical support brackets (19, 20) carried by a base plate (21) attached to the vertical frame supports (11, 12), spur gears (22, 23) connected to an extremity of said printing rollers (15, 16) for the rotation thereof in response to driver gear means (24, 25) connected thereto and supported by rotatable drive shafts (26, 27), a vertical shaft (34) for driving said drive shafts (26, 27) being supported by the said frame (10) and rotatably driven by a power source (35) attached to an extremity thereof, a pair of reciprocal fluid rams (48) disposed to receive switching signals from said control device (160) in proximity to the roller extremities and supported by said spaced apart brackets(19, 20) and each having depending plungers (47) each pivotally connected to linkage arms (42, 43) whose extremities functionally engage the said linkage means (50, 51, 52, 53) connected to the suspended printing rollers (15, 16), the said fluid rams (48) being reciprocally responsive to the switching signals for functionally causing the printing rollers (15, 16) to engage and disengage each other contact wise during the course of colour printing and non-printing in accordance with the signals indicative of the colour sequence, -and further characterized in that the yarn assembly processing devices (3, 4) comprise carrier support means (97) for receiving and transporting the printed yarn assembly (95) leaving said printing machine (2), first heat control means (96) for receiving the said carrier supported yarn assembly (95) and applying heat thereto for the colour fixation thereof, yarn separation means including bath enclosures (101, 102, 103) for removing excess dyes, dissolving cross-fibers holding yarns in place and final wash of the separated yarns, second heat control means (106) for receiving the supported separated yarns (105) and drying same, and yarn receiving means for receiving the separated dried yarns (105) from the second heat control means (106) for storing the yarns or directing the yarns into looms for immediate use to produce the desired design.

Drawing